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Procedia CIRP 7 (2013) 311 – 316

Forty Sixth CIRP Conference on Manufacturing Systems 2013

Development and research of environmentally friendly dry

technological machining system with compensation
of physical function of cutting fluids
Vereschaka A.A.a*, Vereschaka A.S.a, Grigoriev S.N.a, Kirillov A.K.a, Khaustova O.U.a
a
- Moscow State Technological University STANKIN, Vadkovsky per. 1, Moscow 127994, Russia

* Corresponding author. Tel.: +7-499-972-9449 ; .E-mail ecotech@rambler.ru

Abstract

This paper presents the results of researches on development of technological system of environmentally friendly dry
cutting with compensation of physical effects of cutting fluid. The proposed technological system includes cutting tool
with nano-scale multi-layered composite coating, generating device of ionized gas environment which supplied to the
machining area and the exciter unit of ultrasonic vibrations that enhance penetrating ability of ionized gas environment
into the contact areas of cutting tool. The conducted researches have shown high efficiency of the developed
technological system of environmentally friendly cutting not only in comparison with dry cutting, but also in
comparison with traditional technologies using cutting fluids.

© 2013 TheAuthors.
2013 The Authors.Published
Publishedbyby Elsevier
Elsevier B.V.
B.V.
Selection and/or
Selection and peer-review
peer-review underunder responsibility
responsibility of Professor
of Professor PedrodoFilipe
Pedro Filipe CarmodoCunha
Carmo Cunha

Keywords: environmentally friendly machining; ionized gas environment; nano-scale multi-layered composite coating; machining; tool life;
roughness; residual stresses; fatigue strength

absorption of gases during the machining [1,2]. Besides,

1.Introduction the machining processes with use of CF lead to
significantly higher production costs, which constitute
In general, the tasks to improve efficiency of cutting at 25-30% of the total cost of machining, and CF represent
the source of negative technogenic impact on the
the development of new technological processes
environment and health of personnel [1,3,4].
associated with increased machining productivity mainly
The obvious strategy of development of manufacturing
through the growth of the cutting speed and application
processes is the creation of technological machining
of a large amount of cutting fluids (CF) [1,2,3,4].
Meanwhile, use of new technological processes with systems to eliminate the use of cutting fluid with partial
or full compensation of their physical functions.
high and ultra high cutting speeds is characterized by
However, till now the practical application of such
decrease of penetrability of CF into the contact areas of
systems is very limited due to a high enough level of
the tools even with their abundant supply to the
thermomechanical effects on the technological system
machining area and corresponding decrease in its basic
physical effects [1,2,3]. In some cases, the use of CF is for cutting non-use of coolant [5,6].
not recommended at all because of the high probability The object of this research is to develop and research
technologies dry machining with compensation of
of decrease of physical and mechanical properties of
physical effects of CF.
some materials (alloys of titanium, magnesium,
beryllium, etc.) due to their high propensity to surface

2212-8271 © 2013 The Authors. Published by Elsevier B.V.

Selection and peer-review under responsibility of Professor Pedro Filipe do Carmo Cunha
doi:10.1016/j.procir.2013.05.053
312 A.A. Vereschaka et al. / Procedia CIRP 7 (2013) 311 – 316
2. Experemental
Preconditions. Analysis of key aspects of dry cutting
with high thermal stresses action on practically all
elements of cutting system allowed to formulate
scientific tasks to develop a methodology of
environmentally friendly technological machining
system (EFTMS), in which high thermal stresses of dry
cutting system is reduced through the use of elements
that compensate the basic physical effects of CF. The
proposed EFTMS system is characterized by
intensification of convectional processes of heat
abstraction from machining area (cooling function of
CF), decrease of power of frictional heat sources
(lubricating function of CF), and decrease of surface
energy of local volumes of material being machined
(plasticizing function of material being machined.) [1].
To compensate the physical effects of in dry cutting
the following technological machining system, which
includes three main elements (Figure 1), is offered:
cutting tool (1) with nano-scale multi-layered
composite coating (NMCC), including wearresistance
surface layer, intermediate and adhesive sublayers;
system of generation and supply of ionized gas
environment (IGE) directly into the contact areas
between of cutting tool with NMCC and material being
machined (4);
system of generation ultrasonic vibrations (USV)
applied to the cutting tool in the direction of the cutting
speed vector (7).
IGE represent as an important element of the developed
EFTM-system. IGE introduction into the cutting area
contributes to compensation of cooling, lubricating and
plasticizing physical effects of CF that appear in cutting
process with use of CF. The developed version of
EFTMS used ionization system of gas environment by
corona discharge [1,2].
9 described by the Gibbs equation [1]:
10 8 7
4
5 6
2 volume of phase in contact with adsorbing surface,
11 3
7 mol/m3; is specific surface energy of adsorbent, J; R is
14 V 1
4
12
13
Fig. 1. Basic diagram of environmentally friendly
machining system:
1- cutting tool with nano-scale multi-layered composite
coating (NMCC, 2); 3 - chips; 4 - system of generation
of ionized gas environment;- 5,6 power source for
system of gas environment ionization; 7,8,9,10 - electric
contactors for polarity change of corona discharge;
11,12,13,14 - system of admission of the gas
environment (air).
IGE represent an important element of the elaborated dry
cutting system. IGE introduction to the cutting area
contributes to compensation of cooling, lubricating and
plasticizing physical effects that appear in cutting
process with use of cutting fluid.
The developed version of EFTMS used of gas
environment ionization by corona discharge [1,2].
Kinetic energy WK of ionized component of the gas
environment flow, which determines its penetrating
ability, can be defined from the following formula:
WK = W i c (1)
where Wi is initial energy of gas flow components (it
represents a function of pressure and flow density); eZ is
ratio of gas environment charges; Uc is value of negative
potential of cathode at excitation of corona discharge.
Analysis of the formula (1) shows that penetrating
ability and reactivity of IGE, and, therefore, the
possibility to compensate the effects of F, strongly
depend on the charge degree, number and energy of
ions. Adsorption has a significant effect on the activity
of IGE due to penetration, migration and localization of
ions on chemically pure surface of tool material (TM)
and materials being machined (MBM). Part of excessive
energy of ions Wi is being spent on binding IGE
particles, and that leads to a decrease in the surface
energy of newly formed surfaces, that is, adsorption is
being observed. Boundary adsorption layers on the
surface have high mechanical strength and can withstand
without breaking the high pressure of 106 MPa, and the
dependence of adsorption from temperature can be
GS = - C/RT(d /dC); (2)
where C is equilibrium concentration of adsorbent in
gas constant; is temperature, K.
IGE contributes to the intensification of chemical
processes, since it contains extremely active and mobile
ions, active molecules, atoms and radicals that interact
with chemically clean surfaces TM and MBM. IGE is
the most effective in terms of acceleration of chemical
reactions and the formation of protective films of type of
MexOy; MexNy; MexCy; MexCyNz;MexOyNz, MexOyCz. In
this study, cleaned air was used as gas environment.
When IGE is in the form of cleaned air, firstly, oxygen
with a boiling point of about 90 K is being adsorbed and
only then nitrogen with a boiling point of 77 K is being
 A.A. Vereschaka et al. / Procedia CIRP 7 (2013) 311 – 316
adsorbed. Therefore, thermodynamically, initial
reactions of the formation of oxides are most possible,
and then reactions of the formation of nitrides, carbides,
and mixtures thereof.
Therefore, thermodynamically, initial reactions of the
formation of oxides are most possible, and then
reactions of the formation of nitrides, carbides, and
mixtures thereof.
In accordance with the Cabrera-Mott hypothesis, ions
and electrons in a chemically adsorbed film are moving
independently of each other. The mechanism of
formation of thin oxide films is in passage through a thin
mono-layer of metal electrons to oxygen with a very
high influence of temperature on the rate of growth of
films that reach a critical thickness (by durability) at
values of 2 10-4 centimeters. Average time of presence
of molecules on surface of the tool can be estimated by
the following formula:
= 0·e
Q/RT
; (3)
where is time of molecular vibration (10-13- 10-12 s); e
is base of natural logarithms; Q is heat of adsorption that
reaches 8,000 42,000 W/mol in physical adsorption.
Even at a relatively low degree of ionization, which
reaches up to 3-12%, IGE can be considered as a kind of
activated complex with extremely high penetrating
ability and possibility of formation of highly stable
chemical and physical films, adapted to the level of
energy impact, corresponding to conditions of the
cutting process. In this respect, IGE is able to completely
compensate the lubricating effects of cutting fluids
(coolants).
To form coatings, processes of filtered catodic vacuum
arc deposition (FCVAD) [4,7,8-10] were used that
allowed to synthesize nano-dimensional multi-layered
composite coatings (NMCC) based on three-layer
systems [8]. Such NMCC systems included triboactive
wearresistance surface layer, transition and adhesive
sublayers. The surface layer (of type of TiCrAlN,
ZrCrAlN, TiNbZrCrAlN, etc.) contained the active
elements in the form of supersaturated solid solutions
(Al, Ti, Zr, etc.), capable of forming at temperatures of
cutting the thin antifriction films (for example, Al2O3,
AlN, ZrO2, TiO2, etc.) as a result of plasma chemical
reactions with elements of the IGE (O+, N+). The
transition layer based on nitrides of one of metals of the
surface layer (TiN, ZrN, AlN, etc.) provided strong
adhesion of the upper and lower layers and also carried
out the barrier function with respect to thermal flows and
diffusion of the contact area to the tool. The purpose of
the adhesive underlayer was to implement strong
adhesive bond of NMCC with the substrate of TM, and,
therefore, it was formed on the basis of elements and
compounds with metallic bond, the most suitable for the
purpose.
High-speed machining operations and cutting of hard-to-
313
machining materials are characterized by a sharp
decrease in the penetrating ability of F due to a sharp
increase in the density of contact between the MBM
and the CTM material and relative slowdown in the rate
of CF penetration in the contact areas of cutting tool.
Therefore, the third element was introduced in the
EFTMS system a device of generation of ultrasonic
vibrations (USV), applied in the direction of cutting
speed, which allowed to determine discreteness of the
CTM contact with the BMB and significantly improved
penetrating ability CF.
Experimental technique. As object of research were
used inserts made of cemented carbide with NMCC for
high speed machining of hardened steels and machining
of hard-to-machining alloys.
A pilot lot of cutting inserts of SNUN form was made of
carbides grates of V 10 , V 13, T14K8 (ISO
K30-K40, S10-S20, P20) with a with nose radius r=0.8
mm. The cutting inserts were divided(3) into groups, one of
which was used for studies of physical and crystal-
chemical properties, and the other group was used to
study cutting properties of the tool equipped with coated
carbide inserts. The cutting tools equipped with carbide
inserts with developed NMCC, standard coating and
without coating were used. The study was conducted at a
longitudinal turning at a universal lathe machine 16K20
with thyristor-controlled drive that allowed to maintain
the cutting speed at a pre-set level, when the diameter of
the workpiece changed. At carrying out of researches
cutting properties of the tools used following condition
of machining: for 45 (HB200) with the cutting speed
V=80-350 m/min; feed f=0.1-0.25 mm/rev; depth of
cutting ap=0.5-0.15 mm, for titanium alloy VT9 (VT9)
(2.8-3.8% Mo, 1.0-2.0% Zr, 5.8-7.0% Al, 0.25% Fe),
when v=80-100 m/min; f=0.5-0.3 m/rev; ap=1.0-1.5 mm,
for heat-resistant alloy HN77TUK (19-22% Cr; 2,4-2,8
b=930-1080 MPa) at v=20-40 m/min; f=0.1-
0.15 m/rev; ap=0.5-1.0 mm. Failure criteria of the tool
equipped with carbide inserts was flank wear land run-
out VBmax=0.5 mm.
The study was also conducted for such characteristics of
surface quality after machining with use of the IGE as a
roughness, magnitude and a sign on residual stresses,
level gas-saturated metallic surfaces by such elements as
hydrogen, oxygen, nitrogen etc.[1,2].
The studies of roughness of workpiece surface were
carried out immediately after cutting without removing
the workpiece from the machine tool.
In assessing residual stresses that varied with the depth
of removed layers, we took into account not only
measured deformation for each current depth, but also
the stresses that relaxed as a result of the removal of the
previous layers. The numerical value of residual stresses
and the configuration of their distribution in depth of the
subsurface layers of the processed workpiece surface
with nonequilibrium deformations were determined at
automated workbench. Special software package
314 A.A. Vereschaka et al. / Procedia CIRP 7 (2013) 311 – 316

provided the calculation of residual stresses in real time The study has found out that the wear resistant layer
for prismatic samples at beam-and-girder or single-sided TiCrAlN of NMCC (at processing of Ni-alloy
support. HNN77TUK) increases the cutting properties of the tool
Ultimate strength under cyclic loading of samples made of cemented carbide due to the reduction of
subjected to processing with use of the proposed EFTMS mechanical and thermal stresses on its contact areas and
technology was described graphically by a fatigue curve. due to intensification of tribooxidation processes that
The curve can be analytically represented in the form of result in the formation at the tool contact areas of
power or exponential function of dependence of stress antifriction films with nano-dimensional thickness of
from the number of cycles N. N=2 107 cycles were taken type of TiO2 and Al2O3, which improve the state of
as the base for studies for samples of alloy VT9. The cutting system by further reduction of friction.
results of the fatigue tests were presented in coordinates The results of the study of the possibility of using the
lg N. N=2 107 cycles were taken as the base for developed system of technological cutting of EFTMS in
studies for samples of alloy VT9. For fatigue testing, the full and two-element version (NMCC and IGE) of steels
research facility allowing automatic calculation of and titanium alloys also confirm its high efficiency
ultimate stresses was used. (Table 1)
T, min
3. Research results and discussion
6
The main parameters of EFTMS process were
optimized. It was found out that the high efficiency of 12
the process, which is determined by increase of tool 5
wear resistance with developed NMCC and the 10
improvement of quality of machined surfaces are 4
achieved at: 8
simultaneous feed of IGE from the rake and flank faces
3
of the tool (see Fig. 1);
6
purified air pressure p=0.25-0.3 MPa;
distance of plasmatrons from machining area L=40-50
mm; 2
corona discharge current I=50 mA.
4
The following tooling systems were used: 1
for machining of steel 45 T14K8-(Ti-TiN-TiCrAl)N;
for machining of nickel alloy XN77TUP VRK13-(Ti- 3
TiN-TiCrAlN);
for machining of titanium alloy VT9 VK10XOM-
(Zr-ZrN-ZrCrAlN).
The results of cutting tests of the tool equipped with 2
inserts made of cemented carbide at machining of
different materials are shown in Figure 2, and Table 1.
It can be seen from the presented data that for the 1
studied range of cutting speeds, the dependences T=f(V)
are of non-monotonic nature, which is connected with
change of nature and mechanisms of wear of the carbide
tools. In particular, increase in cutting speed leads to a
18 25 35 50
significant increase in temperature, which in turn causes
weakening and subsequent destruction of adhesive bonds V, m/min
in the "MBM-CTM" system, increases of intensity of
Fig. 2. Dependence of the tool life T at VB max=0.5 mm
diffusion processes, which is the cause of intense wear
from the cutting speed v in longitudinal turning of nickel
of the tool (especially of the one without coating).
alloy HNN77TUR with f=0.15 mm; ap=1.0 mm:
1 dry turning by the tool equipped with inserts of
It should be noted that in the whole range of the studied
cutting speeds of chromium-nickel alloy HNN77TUR, carbide VRK13; 2 turning by the tool of VRK13 with
standard cutting fluid; 3 turning by the tool of
the developed EFTMS system is the most effective in
VK10XOM with compressed air (pa=3 Pa), 4 turning by
comparison with the standard processing technologies
the tool of VRK13 with feed of IGE; 5 turning by the
(Figure 2, curve 6). Analysis of the reasons for that can
tool of VRK13-TiN (arc-PVD); 6 turning with the use
be explained as follows.
of the developed EFTMS technology by tools of
VRK13-(Ti-TiN-TiCrAlN).
 A.A. Vereschaka et al. / Procedia CIRP 7 (2013) 311 – 316 315

It also found a significant favorable effect of ultrasonic

vibrations on cutting system. In particular, the use of a 50
three-component system of EFTMS allows to improves 0 20 40 60 80 100
the life of the tool 10 times, when turning chrome-nickel 0

Residual stresses, MPa

alloy HNN77TUK (Figure 2), steel 45 by 9.6 times, and
titanium alloy by 6.4 times due to a significant -50
improvement in penetrating ability of IGE (Table 1).
-100

Table 1. Cutting test result. -150

Tool life T, min at VBmax=0.5 mm -200

Cutting Cutting condition aa. Depth of occurrence, m
tool Dry Cut- Com. IGE at IGE
100
cut- ting Air at with
0 20 40 60 80 100 120
ting with =3.0 [Pa] USV 0

Residual stresses, MPa

CF [Pa]
-100
Machining of steel 45
3,0 7.65 5.8 6.5 7.5 -200
- -300
4.8 6.0 5.9 6,2 8.8
TiN,
(stan- -400
b. Depth of occurrence, m
dard)
14 8- 12.0 22 15.0 24.5 28.8 50
0 20 40 60 80 100 120
Ti-TiN-
TiCrAlN, 0
Residual stresses, MPa

(FVAD)
-50
Machining of titanium alloy VT9
-100
V 5.0 - 6.2 8.9 12
-150
V 12.4 - 15.0 18.4 22.0
-200
-ZrN, Depth of occurrence, m
c.
V 11.4 - 11.0 15.2 32.2
-Zr- Fig.3. Curves of residual stresses in surface layer of the
ZrN- samples obtained in longitudinal turning of titanium
ZrCrAlN alloy VT9 at V=70 m/min; f=0,15 mm/min; ap=1,0 mm
(FVAD) in different conditions :
a dry cutting; b cutting with cooling by standard cutting
It was found out that with the use of the EFTMS system, fluid; c cutting with use of EFTMS.
unevenness of the processed surface decreases as the
cutting speed increases, which is connected with the The results of the studies of gas saturation of surface
coating ability to reduce the propensity of the tool layers of titanium alloys with hydrogen and oxygen have
material to deposition because of passivation of adhesion shown that the quantitative content of oxygen and
activity of carbide. hydrogen for the EFTMS technology is virtually
The results of the study of residual stresses on the identical to the content of those elements in surface of
example of machining of titanium alloy VT9 by the tool the samples at dry machining.
equipped with inserts of carbide grade VK10XOM-(Zr- The research results of the fatigue strength of the
ZrN-ZrCrAlN) for different machining conditions, samples of alloy VT9, presented in Figure 4, have shown
including the use of the EFTMS process at v=70 m/min; the following. After dry machining by the tool made of
f=0.15 mm/rev; ap=1.0 mm are shown in Figure 3. carbide grade VK10XOM, machining with supply of
Analysis of research data of residual stresses shows that compressed air to the machining area, and machining by
the machining with the use of the EFTMS system led to the tool made of carbide grade VK10XOM-ZrN, the
the formation in surface of favourable residual samples have shown virtually the same durability period
compressive stresses. This indicates a rather effective =630-670 MPa (curves 1-3, Figure 4). The best results
cooling of the machining area with decrease of power were shown by the samples, worked with the use of the
frictional heat sources.
316 A.A. Vereschaka et al. / Procedia CIRP 7 (2013) 311 – 316
EFTMS system and subsequent shot peening
(compulsory finishing processing operation) (curve 6,
Figure 4). The sample have shown the durability period
=760 MPa, and that complies well with the
requirements to the parameter for aircraft engine
manufacturing.
MPa
6 fatigue strength of parts made of titanium alloys
800
750
5
700
4
3 References
2
650
1 properties of a superficial layer at use of ecologically friendly
105 107 N,Hz
Fig.4. Fatigue curves of samples of alloy VT9 processed
in different conditions:
1- dry cutting; 2 - cutting with compressed air feed at
p=0.25 MPa;
3- cutting with feed of standard cutting fluid; 4- cutting
by the tool equipped with inserts of VK10HOM-ZrN; 5-
cutting with use of developed technological EFTMS
system; 6- cutting with the EFTMS and subsequent shot
peening.
Conclusion
The studies conducted allowed developing of the
technological system of environmentally friendly dry
machining with compensation of physical effects of
cutting fluids, which is proposed to be used to replace
traditional machining technologies with use of cutting
fluids. The developed technological system includes
cutting tool with nano-scale multi-layered composite
coating, generating device of ionized gas environment
supplied to the machining area and the exciter of
ultrasonic vibrations that enhance penetration of ionized
gas environment on the contact areas of cutting tool.
The studies have confirmed the high efficiency of the
developed technology system in machining steel,
titanium and hard-to-machining nickel alloys. In
particular, the study has shown that the use of the
developed system of cutting decreases roughness of
worked surface and forms more favourable residual
compressive stresses. The study has found out that
machined with the use of the proposed technology,
complies with the level of technical requirements for the
strength of titanium alloy products.
The developed system is recommended for semi-
finishing processing of construction steel and heat-
resistant steels, titanium and nickel alloys (ISO P10-P20,
M10-M20, S10-S20).
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